Download Char-Broil 463251713 Use & care guide

Use & Care Guide
Model: 5729581
FOP
Natural Gas Conversion Kit
This Natural Gas Conversion Kit can be used ONLY with
Dual Fuel™ grills.
If you have questions or need assistance during assembly, please call 1-800-241-7548 (USA) or 1-800-387-6057 (Canada)
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
WARNING
DANGER
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handling this product.
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance
and immediately call your gas supplier or your
fire department.
WARNING
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.
2. An LP Tank not connected for use shall not
be stored in the vicinity of this or any other
appliance.
DANGER
Call the Grill Information Center for Help and Parts
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
Missing Parts? Assembly Questions? Operation Problems?
Before returning grill to store, call 1-800-241-7548
WARNING
Do not attempt to repair or alter this conversion kit for any
assumed defect. Any modification to this assembly will void
your warranty and create the risk of a gas leak and fire. Use
only authorized replacement parts supplied by manufacturer.
To Installer/Assembler: Leave these instructions with
consumer.
To Consumer: Keep this manual for future reference.
WARNING
WARNING: Be alert to the possibility of serious bodily injury
if the instructions are not followed. Be sure to read and
carefully follow all of the messages.
CAUTION
CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
WARNING
CAUTION
Some parts may contain sharp edges, especially
as noted in these instructions.
Wear protective gloves if necessary.
CAUTION
•
•
Read and follow all Safety, Assembly,
and Use and Care Instructions in this
Guide before assembling and cooking
with this grill.
Failure to follow all instructions in this
Use and Care Guide may lead to fire or
explosion, which could result in property
damage, personal injury or death.
For residential use only. Do not use for commercial
cooking.
Printed in USA
2
5729581 • 3498886 • 12-20-10
TABLE OF CONTENTS
Warning & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONNECTING YOUR GRILL TO THE NATURAL GAS SOURCE:
1. A professionally-installed shut-off valve between the supply
piping and the socket is recommended, but not required, by
the National Fuel Gas Code. Socket connection must be made
outdoors.
2. Coat the gas supply pipe nipple with gas resistant pipe dope or
approved teflon tape. Screw socket onto gas supply pipe
(house gas source) as shown in Figure A below, and wrenchtighten.
Grill Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CAUTION
Section A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Section B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
The quick disconnect socket should never be connected to the
grill. Direction of gas flow is indicated on the socket.
Section C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
Section D . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14
Quick disconnect socket
House piping
Section E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Section F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
USE & CARE
Natural Gas Connections and Service Regulators
Above 1/2 psi.
Prior to 1998, all residential gas service regulators were set with
an outlet pressure of 7 inches water column.
In the 1998 edition of NFPA 54, the National Fuel Gas Code, a
change was made allowing service regulators of 2 and 5 psi.
With this change it was also required that an in line regulator be
connected between the service regulator and the appliance
regulator if the 2 or 5 psi system is used. This additional regulator
is not supplied with the product.
It is possible for a consumer, making the connection themselves,
or a plumber, not checking, to tap into a 2 or 5 psi line. If a
pressure of 2 psi or greater is supplied to the appliance regulator
on certain grills it will shut down and not deliver any gas to the grill.
The included quick disconnect socket and hose should not be
used at pressures above 1/2 psi.
If the quick disconnect socket, hose, and grill are properly
connected and still not getting gas, delivery pressure needs to be
verified. If pressure is greater than 1/2 psi, make sure that an in
line regulator is present.
Once the grill has been over-pressured, the regulator may or may
not have been damaged. The best practice is to replace the
regulator.
WARNING
Do not use hard metal piping of any kind to connect this
type of grill to natural gas source. Use only hose
specified by manufacturer. Using hard metal piping or
convoluted metal tubing is an unsafe practice. Movement
of the grill can cause breakage of metal pipe.
Figure A
3. Pull back the sleeve on the quick disconnect socket and insert
the unattached end of the gas hose into the socket. Release the
sleeve and continue pushing the hose into the socket until the
sleeve snaps into the locked position. See Figure B.
Gas hose
Sleeve
Figure B
4. When the quick disconnect socket and the gas hose are
connected, a valve in the socket opens automatically to permit
full gas flow. When the gas hose is disconnected, the valve in
the socket instantly and positively shuts off the flow of gas.
Because the valve in the socket positively shuts off the flow of
gas, the grill can be disconnected from the gas source by
disconnecting the gas hose from the quick disconnect socket.
The socket should be left attached to the gas source (house
piping). Figure C shows properly connected hose and socket.
3
The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing on that system at test pressures in excess of 1/2
psig (3.5kPa).
The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 psi (3.5kPa).
USE AND CARE CON’T.
Figure C
With proper assembly, the gas hose cannot be removed without
pushing the quick disconnect sleeve back. To disconnect, push
sleeve back and pull plug out of sleeve (this automatically shuts
off gas).
Please Note: Hose and assembly are C.S.A. listed for natural
gas, manufactured gas, mixed gas and for liquefied petroleum
and for LP Gas-Air mixtures on basis of 0.64 specific gravity for
1000 BTU’s per cubic foot of gas at 0.3 in. water column
pressure drop. Only ANSI Z21.54 approved hoses should be used
with this grill.
PARTS LIST
Key
Qty.
A
B
C
D
E
F
G
5
1
1
3
1
4
4
Description
Part No.
Main & Sideburner Natural Gas Bezel
Orifice Driving Tool
10 ft., 3/8” Natural Gas Hose
Natural Gas Orifice (Black Dot-# 54)
Natural Gas Orifice (Red Dot-1.45mm)
Natural Gas Orifice (White Dot-1.30mm)
Natural Gas Orifice (Orange Dot-1.25mm)
3499466
80004378
3496263
80007767
80007768
3499688
3499248
Note: Illustrations are not to scale.
#54
Black Dot
D
A
B
C
1.30mm
White Dot
F
Tools required for assembly:
Orifice Driving Tool - Provided
Adjustable Wrench - Not Provided
Standard #2 Phillips Screwdriver - Not Provided
NOTE: Magnetic tip screwdrivers are recommended, but not required.
4
1.45mm
Red Dot
E
1.25mm
Orange Dot
G
Model 463269411
For Conversion Use Sections:
A, B
Parts Required:
4- Bezels
1 -10’ Hose
1-Orifice Driving Tool
4-1.25mm Orifices (Orange Dot)
Model 463269311
For Conversion Use Sections:
A, C, E
Parts Required:
5 - Bezels
1 - 10’ Hose
1 - Orifice Driving Tool
4 - 1.30mm Orifices (White Dot)
1 - 1.45mm Orifice (Red Dot)
Model 463269211
For Conversion Use Sections:
A, D, E
Parts Required:
4 - Bezels
1 - 10’ Hose
1 - Orifice Driving Tool
3 - #54 Orifices (Black Dot)
1 - 1.45 Orifice (Red Dot)
Model 463269111
For Conversion Use Sections:
A, D, E
Parts Required:
4 - Bezels
1 - 10’ Hose
1 -Orifice Driving Tool
3 - #54 Orifice (Black Dot)
1 -1.45MM (Red Dot)
5
Model 463269011
For Conversion Use Sections:
A, F
Parts Required:
2- Bezels
1 -10’ Hose
1-Orifice Driving Tool
6
Section A
A1
First, make sure all Control Knobs are in the OFF position, LP tank valve is closed, and Tank is disconnected from Regulator and
removed from Grill.
Next, open Lid and remove Warming Rack, Cooking Grates, and Heat Diffusers.
Your Grill may differ from illustrations shown. This manual covers a variety of grills styles, use pictures as reference only.
Warming Rack
Lid
Cooking Grates
(2 or 3 depending on Unit purchased)
Heat Diffusers
A2
Using a wrench (not provided) remove LP Regulator Hose Assembly from Manifold Connection. Save removed LP Regulator Hose
assembly for converting back to LP Tank Gas. Your LP Regulator hose will be located under the Sideburner Shelf.
6
Manifold
Connection
LP Regulator
Hose Assembly
7
A3
Position Natural Gas Hose Assembly behind cart up to Manifold Connection.
Secure the Natural Gas Hose Assembly, to Manifold Connection, using a wrench (not provided).
Manifold
Connection
Natural Gas
Hose Assembly
A4
Leak Testing Natural Gas Hose
Turn all grill knobs to OFF.
Brush soapy solution onto areas where bubbles are shown in picture.
If “growing” bubbles appear, there is a leak. Retighten connections. If leak cannot be stopped do not try to repair. Call Char-Broil for
replacement parts.
Manifold
Connection
Natural Gas
Hose Assembly
8
Leak test this
connection
Section B
B1
Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.
Burner
Hitch Pin
Front of
Firebox
Hitch Pin
Carryover Tube
Burner
B2
Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed
orifices for converting back to LP Tank Gas.
Replace with natural gas Orifices provided with Kit (1.25mm-Orange Dot) and tighten to valve end, ensure Orifice is not cross
threaded.
Firebox Burner Opening
Orifice
Orifice
Valve
Front of
Firebox
Orifice Driving Tool
Orifice Driving Tool
9
Section B Con’t.
B3
WARNING
Bezels must be replaced one at a
time. Removing more than one bezel
at a time may cause misalignment of
manifold.
Pull the Tube Burner Control Knob off of Valve Stem.
Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank
Gas.
Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using
previously removed Screws and Washers. Assure proper alignment with control knob before fully tightening. Note: New bezels will
change the rotation for the control knob to properly control ignition and flames for your grill.
Press Control Knob back onto Valve Stem. Make adjustments needed to Bezel for free movement of Control Knob
Repeat for each Bezel.
Bezels
Valve
Stem
Lock Washers
Screws
el
n
l Pa
ntro
Co
Tube Burner
Control Knobs
Bezel
B4
Reinstall Tube Burners
Insert Tube Burners into Firebox Burner holes over Valves with Ignitor Assembly downward, making sure Tube Burner engages Valve
properly. See diagram below.
Secure Tube Burners to Burner Brackets with previously removed Hitch Pins. Replace Carryover tubes and secure with Hitch Pins
previously removed. Reference illustration B1.
Incorrect
burner-to-valve
engagement
Correct
burner-to-valve
engagement
Tube Burner
10
Section C
C1
Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.
Burner
Hitch Pin
Front of
Firebox
Hitch Pin
Carryover Tube
Burner
C2
Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed
orifices for converting back to LP Tank Gas.
Replace with natural gas Orifices provided with Kit (1.30mm-White Dot) and tighten to valve end, ensure Orifice is not cross threaded.
Firebox Burner Opening
Orifice
Orifice
Valve
Front of
Firebox
Orifice Driving Tool
Orifice Driving Tool
11
Section C Con’t.
C3
WARNING
Bezels must be replaced one at a
time. Removing more than one bezel
at a time may cause misalignment of
manifold.
Pull the Tube Burner Control Knob off of Valve Stem.
Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank
Gas.
Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using
previously removed Screws and Washers. Assure proper alignment with control knob before fully tightening. Note: New bezels will
change the rotation for the control knob to properly control ignition and flames for your grill.
Press Control Knob back onto Valve Stem. Make adjustments needed to Bezel for free movement of Control Knob
Repeat for each Bezel.
Bezels
Valve
Stem
Lock Washers
Screws
el
n
l Pa
ntro
Co
Tube Burner
Control Knobs
Bezel
C4
Reinstall Tube Burners
Insert Tube Burners into Firebox Burner holes over Valves with Ignitor Assembly downward, making sure Tube Burner engages Valve
properly. See diagram below.
Secure Tube Burners to Burner Brackets with previously removed Hitch Pins. Replace Carryover tubes and secure with Hitch Pins
previously removed. Reference illustration B1.
Incorrect
burner-to-valve
engagement
Correct
burner-to-valve
engagement
Tube Burner
12
Section D
D1
Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.
Burner
Hitch Pin
Front of
Firebox
Hitch Pin
Carryover Tube
Burner
D2
Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed
orifices for converting back to LP Tank Gas.
Replace with natural gas Orifices provided with Kit (#54 Black Dot) and tighten to valve end, ensure Orifice is not cross threaded.
Firebox Burner Opening
Orifice
Orifice
Valve
Front of
Firebox
Orifice Driving Tool
Orifice Driving Tool
13
Section D Con’t.
D3
WARNING
Bezels must be replaced one at a
time. Removing more than one bezel
at a time may cause misalignment of
manifold.
Pull the Tube Burner Control Knob off of Valve Stem.
Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank
Gas.
Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using
previously removed Screws and Washers. Assure proper alignment with control knob before fully tightening. Note: New bezels will
change the rotation for the control knob to properly control ignition and flames for your grill.
Press Control Knob back onto Valve Stem. Make adjustments needed to Bezel for free movement of Control Knob
Repeat for each Bezel.
Bezels
Valve
Stem
Lock Washers
Screws
el
n
l Pa
ntro
Co
Tube Burner
Control Knobs
Bezel
D4
Reinstall Tube Burners
Insert Tube Burners into Firebox Burner holes over Valves with Ignitor Assembly downward, making sure Tube Burner engages Valve
properly. See diagram below.
Secure Tube Burners to Burner Brackets with previously removed Hitch Pins. Replace Carryover tubes and secure with Hitch Pins
previously removed. Reference illustration C1.
Incorrect
burner-to-valve
engagement
Correct
burner-to-valve
engagement
Tube Burner
14
Section E
E1
Open Sideburner Lid and remove the Sideburner Grate.
From beneath Sideburner Shelf, remove Wingnut.
Remove Sideburner from Shelf.
Sideburner Grate
Sideburner
Wingnut
E2
Using the provided Orifice Driving Tool, unscrew the Orifice from the end of the Sideburner Valve. Save removed Orifice and
Orifice Driving Tool for converting back to LP.
Replace with natural gas Orifice provided with Kit (1.45mm Red Dot) and tighten to valve end, ensure Orifice is not cross threaded.
Orifice
Orifice Driving Tool
Valve
Orifice Driving Tool
15
Section E Con’t.
E3
Pull the Sideburner Control Knob off of Valve Stem. Remove the existing Bezel by removing the two Screws and two Washers securing
bezel to Shelf fascia. Save removed Bezel for converting back to LP Tank Gas.
Install new Natural Gas Bezel (see illustration below) and press Control Knob back onto Valve Stem.
Washer
Screw
Bezel
Valve stem
Sideburner control knob
Bezel
E4
Return Sideburner to Shelf. Make sure Burner engages Sideburner Valve. See illustration below for correct burner-to-valve
engagement.
Secure Burner to Shelf with Wingnut.
Place Sideburner Grate onto Sideburner Pan.
Sideburner Grate
Sideburner
Sideburner
Valve
CORRECT BURNER-TO-VALVE
ENGAGEMENT
Wingnut
Reinstall Heat Diffusers, Cooking Grates and Warming Rack, reference illustration Section A1. for reinstallation.
16
Section F
F1
Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.
Burner
Hitch Pin
Front of
Firebox
Hitch Pin
Carryover Tube
Burner
F2
Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed
orifices for converting back to LP Tank Gas.
This grill is designed to work with Natural Gas once Orifices are removed. No replacement Orifice is necessary.
Firebox Burner Opening
Orifice
Orifice
Valve
Front of
Firebox
Orifice Driving Tool
Orifice Driving Tool
17
Section F Con’t.
F3
WARNING
Bezels must be replaced one at a
time. Removing more than one bezel
at a time may cause misalignment of
manifold.
Pull the Tube Burner Control Knob off of Valve Stem.
Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank
Gas.
Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using
previously removed Screws and Washers. Assure proper alignment with control knob before fully tightening. Note: New bezels will
change the rotation for the control knob to properly control ignition and flames for your grill.
Press Control Knob back onto Valve Stem. Make adjustments needed to Bezel for free movement of Control Knob
Repeat for each Bezel.
Bezels
Valve
Stem
Lock Washers
Screws
el
n
l Pa
ntro
Co
Tube Burner
Control Knobs
Bezel
F4
Reinstall Tube Burners
Insert Tube Burners into Firebox Burner holes over Valves with Ignitor Assembly downward, making sure Tube Burner engages Valve
properly. See diagram below.
Secure Tube Burners to Burner Brackets with previously removed Hitch Pins. Replace Carryover tubes and secure with Hitch Pins
previously removed. Reference illustration B1.
Incorrect
burner-to-valve
engagement
Correct
burner-to-valve
engagement
Tube Burner
18
TROUBLESHOOTING
EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
• Damaged hose.
• Turn off gas at at source. If anything but burned, replace
parts. If burned, discontinue use of product until a plumber
has investigated cause and corrections are made.
Troubleshooting
Problem
Burner(s) will not
light using ignitor.
Burner(s) will not
match light.
Flames blow out.
Possible Cause
GAS ISSUES:
• No gas flow.
Prevention/Solution
• Make sure gas hose is properly connected to grill. If hose is
properly connected, make sure gas source is turned on.
• See “GAS ISSUES:” .
• Match will not reach.
• Use long-stem match (fireplace match).
• Improper method of match-lighting.
• See “Match-Lighting” section of Grill Use and Care.
• Natural gas valve not fully open.
• Open Natural Gas Valve to full open position.
• Inadequate gas pressure.
• Call gas company.
19
NOTES: